Through tubing intelligent completion and method

ABSTRACT

A through tubing intelligent completion including a completion string; one or more isolation seals on the completion string and having an undeployed set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed; and one or more interventionlessly actuable flow control devices in the completion string having a set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed and method.

BACKGROUND

In the downhole industry, boreholes and various levels of completion are used for many different operations. Many of these completions have long lifespans and sometimes the lifespan of the completion is greater than the life of a particular well in which it is installed. In other words, there may be a desire to rework a well before the completion is beyond its actual useful life. Such can be the case with older wells that are not instrumented leading an owner to consider a rework of the well at significant expense and down time. As will be immediately recognized by one of ordinary skill in the art, more instrumentation faster and for less money and downtime would be well received.

SUMMARY

A through tubing intelligent completion including a completion string; one or more isolation seals on the completion string and having an undeployed set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed; and one or more interventionlessly actuable flow control devices in the completion string having a set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed.

A method for upgrading an existing well with an intelligent completion including making up a completion string; one or more isolation seals on the completion string and having an undeployed set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed; and one or more interventionlessly actuable flow control devices in the completion string having a set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed; running the completion string into a production tubing string in a borehole; exiting a downhole end of the production tubing string with the completion string; and deploying the one of more isolation seals.

BRIEF DESCRIPTION OF THE DRAWING

Referring now to the drawings wherein like elements are numbered alike in the several figures:

FIG. 1 is a schematic view of a borehole system as disclosed herein;

FIG. 2 is an enlarged view of one of the control valves in accordance with the teaching hereof

DETAILED DESCRIPTION

Referring to FIG. 1, a borehole system 10 having a tubing string 12 that may be preexisting or may just be preinstalled is illustrated. A through tubing system is taught herein that allows installation of an intelligent completion through an existing tubing string 12, such as production tubing into an open hole 14. The through tubing completion 16 includes a string 18 one or more isolation seals 20 (three shown) and one or more flow control devices 22 (three shown) which in one embodiment will mirror the number of isolation seals 20. These components are run on a capillary coil tubing 24 or similar conveyance through the tubing string 12 and into, in one embodiment, an open hole.

Recognizable to one of ordinary skill is a restriction 26, representing one or more possible restrictions in the tubing string 12. This presents a significant hurdle with respect to running a through tubing intelligent completion such as that depicted in the Figures hereof. In order to have a useful through tubing completion 16, it must be of reasonable size (for example, for a tubing string 12 of 4.5 inch diameter, the restriction 26 will in one instance be 3.75 inches. Accordingly the completion string 18 must have an outside diameter of less than 3.75 inches). Currently available interventionlessly actuatable flow control devices cannot be used while maximizing the completion string size. For purposes of clarity, “interventionlessly” as used herein is intended to mean that a tool need not be run to adjust the valve but rather that adjustment may be done remotely based upon input from a control line or autonomously. Types of control lines contemplated include electric, hydraulic, optic, etc. In accordance with the present invention however, the inventors hereof have solved this persistent problem.

The through tubing intelligent completion 16 provides both zonal isolation and control in a through tubing package. Isolation seals 20 are, in one embodiment, high expansion packers that may be inflatable or swellable, for example, and are hence capable of having a very diminutive diameter prior to deployment allowing them to pass the restriction 26. The control devices 22 must similarly pass through the restriction. As noted above, actuatable devices heretofore were not able to pass through the restriction except for sliding sleeves that require surface intervention by a shifting tool to open or close. The interventionlessly actuable flow control devices of the present invention however, include on board actuators that can be actuated electrically, hydraulically, optically, magnetically pneumatically, etc. and in some embodiments can be actuated automatically pursuant to a controller nearby the device 22. Each of the devices 22 includes a housing 30 having an actuator 32 centrally located therewithin. The actuator in a central position in the housing is made possible by the lack of a central flow channel, which was heretofore common in the art. Rather than trying to retain the central flow channel as would one of ordinary skill in the art and push the actuator to the side of the housing, resulting is a larger overall diameter, the inventors hereof have followed an unconventional path. The devices 22 disclosed herein take advantage of the shapelessness of fluid to reduce the overall housing size. More particularly, the fluid flow that is to be conveyed through the device, bypass flow 46, as distinct from the flow that is selectively admitted or denied entry to the completion 16 through the valve (discussed below), is diverted around the actuator 32 in one or more channels. Although this is represented in FIG. 2 with one bypass flow channel 46, it is to be understood that such channels may be perimetrically located around the actuator and housing. The same overall flow area is achieved by that of a central flow area device but since the flow is spread out it can be thinner in radial dimension and hence allow for the actuator to be housed without increasing housing dimension.

The housing 30 includes, in one embodiment, a poppet type or similar valve 34 having a poppet 36 in operable communication with the actuator 32 and a seat 38. The poppet valve 34 and seat 38 are interposed between an orifice 40 and a flow channel 42 that is in communication with a tubing flow channel 44. Flow through the valve 34 is commingled with bypass flow 46 for delivery uphole in the embodiment where the borehole is intended to produce. The valve 34 may be opened, closed or choked to serve the overall purpose or optimization of flow into or out of the completion 16. Note too that the valve 34 is interventionlessly actuable to selectively admit or deny (or choke) fluid from a particular area while not affecting the fluid flowing through the bypass 46. This therefore allows the selective control of areas or zones of the borehole while not having a resultant effect on other zones or areas that was common with prior art completions. In addition to the flow control, the intelligent completion may also in some embodiments include one or more sensors 48 configured to sense one or more parameters associated with the borehole to optimize production. The one or more sensors 48 may be located anywhere that is convenient along the completion string.

The through tubing completion system as described is capable of passing through the restriction 26 in tubing 12 and thereby facilitates the delivery of an intelligent completion system through an existing tubing string which may have been from a preexisting borehole system or a newly created one where it has been determined that an intelligent completion downhole of an installed tubing string would be beneficial. As one of skill in the art will recognize, the ever-changing conditions in the downhole environment provide ample opportunity for such an upgrade or change in plan.

At a relative uphole end 50 of the completion 16, a set of one or more ports 52 are provided that allow fluid flowing in the completion 16 to exit the tubing 18 and thereby flow into the production tubing 12 for production to the surface.

Finally, it will be noted that the completion 16 is provided, in one embodiment, with a control line 60 that is supplied with a signal (of whatever type may be propagated by the particular type of control line) through a wet connect 62 that connects to a control line 64 from surface.

The system of the invention provides dramatically enhanced functionality over a tubing 12 alone and allows for retrofitment in older wells created before intelligent completions were ubiquitously accepted.

While one or more embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. 

1. A through tubing intelligent completion comprising: a completion string; one or more isolation seals on the completion string and having an undeployed set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed; and one or more interventionlessly actuable flow control devices in the completion string having a set of dimensions smaller than one or more restrictions in a tubing string through which the completion string is deployed.
 2. A through tubing intelligent completion as claimed in claim 1 further comprising a control line in operable communication with one or more of the one or more interventionlessly actuable flow control devices.
 3. A through tubing intelligent completion as claimed in claim 1 wherein the one or more isolation seals are inflatable seals.
 4. A through tubing intelligent completion as claimed in claim 1 wherein the one or more isolation seals are swellable seals.
 5. A through tubing intelligent completion as claimed in claim 1 wherein the one or more interventionlessly actuable flow control devices comprises: a housing; a fluid bypass channel within the housing; an actuator within the housing; and a valve in operable communication with the actuator.
 6. A through tubing intelligent completion as claimed in claim 5 wherein the actuator is disposed centrally of the housing.
 7. A through tubing intelligent completion as claimed in claim 5 wherein the bypass is disposed perimetrically of the housing relative to the actuator.
 8. A through tubing intelligent completion as claimed in claim 5 wherein the valve is a poppet type valve.
 9. A through tubing intelligent completion as claimed in claim 1 wherein the completion string further includes a wet connect.
 10. A through tubing intelligent completion as claimed in claim 1 wherein the completion string further includes one or more sensors.
 11. A through tubing intelligent completion as claimed in claim 1 wherein the completion string further includes a set of one or more ports fluidly communicating the completion string with an annuls thereof.
 12. A method for upgrading an existing well with an intelligent completion comprising: making up a completion string as defined in claim 1; running the completion string into a production tubing string in a borehole; exiting a downhole end of the production tubing string with the completion string; and deploying the one of more isolation seals.
 13. A method as claimed in claim 12 further comprising adjusting one or more of the one or more control devices to optimize production.
 14. A method as claimed in claim 12 wherein the running is on coil tubing.
 15. A method as claimed in claim 12 wherein the deploying is by inflating the one or more seals.
 16. A method as claimed in claim 12 wherein the deploying is by swelling the one or more seals. 